CIB UNIGAS PG60 Operating manual

MANUAL OF INSTALLATION - USE - MAINTENANCE
PG60
PG70
PG81
M039356CB Rev. 1 05/2008
BURNERS - BRUCIATORI - BRULERS - BRENNER - QUEMADORES - ГОРЕЛКИ
Light oil/Biodiesel
double-stage burners
Versions with:
- 12VDC voltage supply
- oleo-static driven fan motor

C.I.B. UNIGAS - M03997CB
2
TABLE OF CONTENTS
WARNINGS ............................................................................................................................................................... 3
PART I: INSTALLATION ........................................................................................................................................... 5
Burner model identification ............................................................................................................................................................. 5
Technical specifications .................................................................................................................................................................. 5
Overall dimensions ......................................................................................................................................................................... 6
Performance curves ........................................................................................................................................................................ 6
MOUNTINGS AND CONNECTIONS .............................................................................................................................................. 7
Packing ........................................................................................................................................................................................... 7
Handling the burner ........................................................................................................................................................................ 7
Hydraulic diagrams for light oil supplying circuits ........................................................................................................................... 8
Installation diagram of light oil pipes ............................................................................................................................................... 9
Determining the diameter of oil supply pipes ................................................................................................................................ 10
About the use of fuel pumps ......................................................................................................................................................... 11
Oil pumps ...................................................................................................................................................................................... 12
Connecting the light oil flexible hoses ........................................................................................................................................... 13
Electrical connections ................................................................................................................................................................... 13
ADJUSTMENTS ........................................................................................................................................................................... 14
Priming the pump .......................................................................................................................................................................... 14
Oil rate setting ............................................................................................................................................................................... 14
Hydraulic scheme - operating principle ......................................................................................................................................... 16
Hydraulic circuit - components arrangement ................................................................................................................................ 17
Air adjustment ............................................................................................................................................................................... 17
Combustion head adjustment ....................................................................................................................................................... 18
PART II: OPERATION ............................................................................................................................................. 19
OPERATION ................................................................................................................................................................................. 19
PART III: MAINTENANCE ....................................................................................................................................... 20
ROUTINE MAINTENANCE ........................................................................................................................................................... 20
Removing the combustion head ................................................................................................................................................... 20
.Correct position of electrodes and combustion head ................................................................................................................... 21
Checking the flame signal ............................................................................................................................................................ 21
TROUBLESHOOTING ................................................................................................................................................................. 22
SPARE PARTS ............................................................................................................................................................................. 23
BURNER EXPLODED VIEW ........................................................................................................................................................ 24
ELECTRICAL WIRING DIAGRAMS ............................................................................................................................................. 26

3
WARNINGS
THIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE
USER.
INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRO-
DUCT INSTALLATION AND MAINTENANCE.
THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SECTION
OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.
CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE..
1) GENERAL INTRODUCTION
zThe equipment must be installed in compliance with the regulations
in force, following the manufacturer’s instructions, by qualified per-
sonnel.
zQualified personnel means those having technical knowledge in the
field of components for civil or industrial heating systems, sanitary
hot water generation and particularly service centres authorised by
the manufacturer.
zImproper installation may cause injury to people and animals, or
damage to property, for which the manufacturer cannot be held lia-
ble.
zRemove all packaging material and inspect the equipment for inte-
grity.
In case of any doubt, do not use the unit - contact the supplier.
The packaging materials (wooden crate, nails, fastening devices, plastic
bags, foamed polystyrene, etc), should not be left within the reach of chil-
dren, as they may prove harmful.
zBefore any cleaning or servicing operation, disconnect the unit from
the mains by turning the master switch OFF, and/or through the cut-
out devices that are provided.
zMake sure that inlet or exhaust grilles are unobstructed.
zIn case of breakdown and/or defective unit operation, disconnect the
unit. Make no attempt to repair the unit or take any direct action.
Contact qualified personnel only.
Units shall be repaired exclusively by a servicing centre, duly authorised
by the manufacturer, with original spare parts.
Failure to comply with the above instructions is likely to impair the unit’s
safety.
To ensure equipment efficiency and proper operation, it is essential that
maintenance operations are performed by qualified personnel at regular
intervals, following the manufacturer’s instructions.
zWhen a decision is made to discontinue the use of the equipment,
those parts likely to constitute sources of danger shall be made har-
mless.
zIn case the equipment is to be sold or transferred to another user, or
in case the original user should move and leave the unit behind,
make sure that these instructions accompany the equipment at all
times so that they can be consulted by the new owner and/or the
installer.
zFor all the units that have been modified or have options fitted then
original accessory equipment only shall be used.
zThis unit shall be employed exclusively for the use for which it is
meant. Any other use shall be considered as improper and, there-
fore, dangerous.
The manufacturer shall not be held liable, by agreement or otherwise, for
damages resulting from improper installation, use and failure to comply
with the instructions supplied by the manufacturer.
2) SPECIAL INSTRUCTIONS FOR BURNERS
zThe burner should be installed in a suitable room, with ventilation
openings complying with the requirements of the regulations in force,
and sufficient for good combustion.
zOnly burners designed according to the regulations in force should
be used.
zThis burner should be employed exclusively for the use for which it
was designed.
zBefore connecting the burner, make sure that the unit rating is the
same as delivery mains (electricity, gas oil, or other fuel).
zObserve caution with hot burner components. These are, usually,
near to the flame and the fuel pre-heating system, they become hot
during the unit operation and will remain hot for some time after the
burner has stopped.
When the decision is made to discontinue the use of the burner, the user
shall have qualified personnel carry out the following operations:
a Remove the power supply by disconnecting the power cord from the
mains.
b) Disconnect the fuel supply by means of the hand-operated shut-off
valve and remove the control handwheels from their spindles.
Special warnings
zMake sure that the burner has, on installation, been firmly secured to
the appliance, so that the flame is generated inside the appliance
firebox.
zBefore the burner is started and, thereafter, at least once a year,
have qualified personnel perform the following operations:
a set the burner fuel flow rate depending on the heat input of the
appliance;
b set the flow rate of the combustion-supporting air to obtain a combu-
stion efficiency level at least equal to the lower level required by the
regulations in force;
c check the unit operation for proper combustion, to avoid any harmful
or polluting unburnt gases in excess of the limits permitted by the
regulations in force;
d make sure that control and safety devices are operating properly;
e make sure that exhaust ducts intended to discharge the products of
combustion are operating properly;
f on completion of setting and adjustment operations, make sure that
all mechanical locking devices of controls have been duly tightened;
g make sure that a copy of the burner use and maintenance instruc-
tions is available in the boiler room.
zIn case of a burner shut-down, reser the control box by means of the
RESET pushbutton. If a second shut-down takes place, call the
Technical Service, without trying to RESET further.
zThe unit shall be operated and serviced by qualified personnel only,
in compliance with the regulations in force.
3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED
3a) ELECTRICAL CONNECTION
zFor safety reasons the unit must be efficiently earthed and installed
as required by current safety regulations.
zIt is vital that all saftey requirements are met. In case of any doubt,
ask for an accurate inspection of electrics by qualified personnel,
since the manufacturer cannot be held liable for damages that may
be caused by failure to correctly earth the equipment.
zQualified personnel must inspect the system to make sure that it is
adequate to take the maximum power used by the equipment shown
on the equipment rating plate. In particular, make sure that the
system cable cross section is adequate for the power absorbed by
the unit.
zNo adaptors, multiple outlet sockets and/or extension cables are per-
mitted to connect the unit to the electric mains.
zAn omnipolar switch shall be provided for connection to mains, as
required by the current safety regulations.
zThe use of any power-operated component implies observance of a
few basic rules, for example:
-do not touch the unit with wet or damp parts of the body and/or with
bare feet;
-do not pull electric cables;
-do not leave the equipment exposed to weather (rain, sun, etc.)
unless expressly required to do so;
-do not allow children or inexperienced persons to use equipment;
zThe unit input cable shall not be replaced by the user.
In case of damage to the cable, switch off the unit and contact qualified
personnel to replace.
When the unit is out of use for some time the electric switch supplying all
the power-driven components in the system (i.e. pumps, burner, etc.)
should be switched off.

4
3b) FIRING WITH GAS, LIGHT OIL OR OTHER FUELS
GENERAL
zThe burner shall be installed by qualified personnel and in com-
pliance with regulations and provisions in force; wrong installation
can cause injuries to people and animals, or damage to property, for
which the manufacturer cannot be held liable.
zBefore installation, it is recommended that all the fuel supply system
pipes be carefully cleaned inside, to remove foreign matter that might
impair the burner operation.
zBefore the burner is commissioned, qualified personnel should ins-
pect the following:
a the fuel supply system, for proper sealing;
b the fuel flow rate, to make sure that it has been set based on the
firing rate required of the burner;
c the burner firing system, to make sure that it is supplied for the desi-
gned fuel type;
d the fuel supply pressure, to make sure that it is included in the range
shown on the rating plate;
e the fuel supply system, to make sure that the system dimensions are
adequate to the burner firing rate, and that the system is equipped
with all the safety and control devices required by the regulations in
force.
zWhen the burner is to remain idle for some time, the fuel supply tap
or taps should be closed.
SPECIAL INSTRUCTIONS FOR USING GAS
Have qualified personnel inspect the installation to ensure that:
a the gas delivery line and train are in compliance with the regulations
and provisions in force;
b all gas connections are tight;
c the boiler room ventilation openings are such that they ensure the air
supply flow required by the current regulations, and in any case are
sufficient for proper combustion.
zDo not use gas pipes to earth electrical equipment.
zNever leave the burner connected when not in use. Always shut the
gas valve off.
zIn case of prolonged absence of the user, the main gas delivery
valve to the burner should be shut off.
Precautions if you can smell gas
a do not operate electric switches, the telephone, or any other item
likely to generate sparks;
b immediately open doors and windows to create an air flow to purge
the room;
c close the gas valves;
d contact qualified personnel.
zDo not obstruct the ventilation openings of the room where gas
appliances are installed, to avoid dangerous conditions such as the
development of toxic or explosive mixtures.
DIRECTIVES AND STANDARDS
Gas burners
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for house-
hold and similar purposes. Safety requirements.
Light oil burners
European directives:
-Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 (Electrical equipment of non-electric appliances for house-
hold and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Heavy oil burners
European directives:
-Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-CEI EN 60335-1 Household and similar electrical appliances - SafetyPart
1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Light oil burners
European directives:
- Directive 90/396/CEE Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 Gas Burners
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods
Gas - Heavy oil burners
European directives:
- Directive 90/396/CEE - Gas Appliances;
- Directive 2006/95/EC on low voltage;
- Directive 2004/108/CEE on electromagnetic compatibility
Harmonised standards :
-UNI EN 676 (Gas Burners;
-CEI EN 60335-1(Household and similar electrical appliances - Safety.
Part 1: General requirements;
- EN 50165 Electrical equipment of non-electric appliances for household
and similar purposes. Safety requirements.
National standards :
-UNI 7824: Monobloc nebulizer burners for liquid fuels. Characteristics
and test methods

C.I.B. UNIGAS - M03997CB
5
Burner model identification
Burners are identified by burner type and model. Burner model identification is described as follows.
Technical specifications
NOTE: Choosing the nozzle for light oil, consider Hi equal to 10200 kcal/kg.
NOTE: Choosing the nozzle for Bioediesel, consider Hi equal to 8950 kcal/kg.
Type PG60 Model G-. AB. S. *. Y.
(1) (2) (3) (4) (5) (6)
(1) BURNER TYPE PG60-PG70-PG81
(2) FUEL G - Light oil A - Biodiesel
(3) OPERATION(Available versions) AB - Double-stage
(4) BLAST TUBE S - Standard L - Extended
(5) DESTINATION COUNTRY * - see data plate*
(6) BURNER VERSION Y - Special version with power supply 12V DC and oil driven air damper jack
BURNERS PG60 G-.. PG70 G-.. PG81 G-..
Output min. - max. kW 145 - 698 291 - 1047 264-1900
Fuel Light oil
Light oil rate min. -max. kg/h 12 - 59 24.5 - 88 22-160
Light oil viscosity cSt @ 40°C 2 - 7.4
Light oil density kg/m30.84
Power supply 12V DC
Total power consumption kW 0.5 0.5 0.5
Index of protection IP40
Approx. weight kg 42 60 76
Operation Double-stage
Operating temperature °C -10 ÷ +50
Storage Temperature °C -20 ÷ +60
Working service * Intermittent
BURNERS PG60 A-.. PG70 A-.. PG81 A-..
Output min. - max. kW 145 - 698 291 - 1047 264-1900
Fuel Biodiesel
Biodiesel rate min. -max. kg/h 14 - 67 28 - 100 25-182
Biodiesel viscosity cSt @ 40°C 1.9 - 6 cSt
Biodiesel density kg/m30.88
Power supply 12V DC
Total power consumption kW 0.5 0.5 0.5
Index of protection IP40
Approx. weight kg 42 60 76
Operation Double-stage
Operating temperature °C -10 ÷ +50
Storage Temperature °C -20 ÷ +60
Working service * Intermittent
PART I: INSTALLATION

C.I.B. UNIGAS - M03997CB
6
Overall dimensions (mm)
S - Standard L - Extended
Performance curves
To get the input in kcal/h, multiply value in kW by 860.
Data are referred to standard conditions: atmospheric pressure at 1013mbar, ambient temperature at 15°C
AAABBBCCCD E F G H K L M N O P W Z
min. max.
PG60 12V S - - 244 - - - - - - Ø153 182 240 - M10 269 190 190 190 - -
PG60 12V L - - 442 - - - - - - Ø153 182 240 - M10 269 190 190 190 - -
PG70 12V S 961 135 310 154 651 263 605 255 351 Ø198 228 300 374 M10 330 216 250 233 529 155
PG70 12V L 1111 135 460 154 651 263 605 255 351 Ø198 228 300 374 M10 330 216 250 233 529 155
PG81 12V S 991 135 340 154 651 263 - - - Ø234 264 300 374 M10 330 216 250 233 529 155
PG81 12V L 1141 135 490 154 651 263 - - Ø234 264 300 374 M10 330 216 250 233 529 155
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
PG60
kW
PG70
kW
BACK PRESSURE IN
COMBUSTION CHAMBER mbar
PG81
kW
-2
0
2
4
6
8
10
0 200 400 600 800 -2
0
2
4
6
8
10
12
14
0 200 400 600 800 1000 1200
0
2
4
6
8
0
2
4
200 400 600 800 1000 1200 1400 1600 1800 20
0

C.I.B. UNIGAS - M03997CB
7
MOUNTINGS AND CONNECTIONS
Packing
The burners are dispatched in wooden pakages whose dimensions are:
PG60: 1200mm x 670mm x 540 mm (L x P x H)
PG70-PG81: 1280mm x 850mm x 760 mm (L x P x H)
Packing cases of this kind are affected by humidity and are not suitable for stacking. The following are pla-
ced in each packing case.
1 burner;
2 oil flexible hoses;
1 oil filter;
1 gasket to be inserted between the burner and the boiler;
1 envelope containing this manual.
To get rid of the burner’s packing, follow the procedures laid down by current laws on disposal of materials.
Fitting the burner to the boiler
To install the burner into the boiler, proceed as follows:
1 make a hole on the closing door of the combustion chamber as described on paragraph “Overall dimensions”)
2 place the burner to the boiler: lift it up and handle it according to the procedure described on paragraph “Handling the burner”;
3 place the 4 stud bolts (5) on the hole of the boiler’s door, according to the burner’s drilling plate described on paragraph “Overall
dimensions”;
4 fasten the 4 stud bolts;
5 place the gasket on the burner flange;
6 install the burner into the boiler;
7 fix the burner to the stud bolts, by means of the fixing nuts, according to the next picture.
8 After fitting the burner to the boiler, ensure that the gap between the blast tube and the refractory lining is sealed with appropriate
insulating material (ceramic fibre cord or refractory cement).
Handling the burner
ATTENTION! The lhandling operations must be carried out by specialised and trained personnel. If these opera-
tions are not carried out correctly, the residual risk for the burner to overturn and fall down still persists.
To move the burner, use means suitable to support its weight (see paragraph “Technical specifications”).
H
PL
Keys
1 Burner
2 Fixing nut
3Washer
4 Sealing gasket
5 Stud bolt
7Blasttube

C.I.B. UNIGAS - M03997CB
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Hydraulic diagrams for light oil supplying circuits
NOTE: in plants where gravity or ring feed systems are provided, install an automatic interception device (see n. 4-Fig. 7).
Fig. 4 - Gravity circuit
Fig. 5 - Ring circuit
Fig. 6 - Suction circuit
Key
1 Manual valve
2 Light oil filter
3 Light oil feeding pump
4 One way valve
5 Flexible hoses
6 Relief valve

C.I.B. UNIGAS - M03997CB
9
Installation diagram of light oil pipes
PLEASE READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNING OF THIS MANUAL.
Fig. 7 - Double-pipe system
The burner is supplied with filter and flexible hoses, all the parts upstream the filter must be installed by the customer. As far as
the hoses connection, see the related paragraph..
Key
1 Burner
2 Flexible hoses (fitted)
3 Light oil filter (fitted)
4 Automatic interceptor (*)
5 One-way valve (*)
6 Gate valve
7 Quick-closing gate-valve (outside the tank or boiler rooms)
(*) Only for installations with gravity, siphon or for-
ced circulation feed systems. If the device installed
is a solenoid valve, a timer must be installed to
delay the valve closing.
The direct connection of the device without a timer
may cause pump breaks.
From tank
To tank

C.I.B. UNIGAS - M03997CB
10
Determining the diameter of oil supply pipes
L= pipeline length in meters
The provided pumps can be installed both into single-pipe and double-pipe systems.
Single-pipe system: a single pipe drives the oil from the tank to the pump’s inlet. Then, from the pump, the pressurised oil is driven to
the nozzle: a part comes out from the nozzle while the othe part goes back to the pump. In this system, the by-pass pulg, if provided,
must be removed and the optional return port, on the pump’s body, must be sealed by steel plug and washer.
Double-pipe system: as for the single pipe system, a pipe that connects the tank to the pump’s inlet is used besides another pipe that
connects the pum’s return port to the tank, as well. The excess of oil goes back to the tank: this installation can be considered self-ble-
eding. If provided, the inside by-pass plug must be installed to avoid air and fuel passing through the pump.
Burners are factory-set for double-stage systems. They can be suited for single-pipe system (recommended in the case of gravity
feed) as decribed before.
To change from a 1-pipe system to a 2-pipe-system, insert the by-pass plug G(as for ccw-rotation- referring to the pump shaft).
Caution: Changing the direction of rotation, all connections on top and side are reversed.
PG60 - PG70: Suntec AJ6 - PG81: Suntec J6
Syphon twin pipe feedI Twin pipe suction feed
SUNTEC AJ6/J6/E6 SUNTEC AJ6/J6/E6
H (m) L (m) H (m) L (m)
ø10ø12ø14ø16 ø10ø12ø14ø16
0 5 13 27 47 0 5 13 27 47
0,5 6 15 30 52 0,5 4 12 23 41
1 7 17 33 58 1 3 10 20 36
2 9 21 40 70 2 2 6 13 24
3 10244780 3 0 3 7 13
4 12285392 4 0 0 0 2
SUNTEC J7CCC/E7 SUNTEC J7CCC/E7
H (m) L (m) H (m) L (m)
ø10ø12ø14ø16 ø10ø12ø14ø16
0 2 7 1629 0 7 162976
0,5 2 8 1833 0,5 6 142667
1 3 10 20 37 1 5 12 22 58
2 4 12 25 44 2 2 7 14 40
3 5 14 29 52 3 0 3 7 21
4 6 17 33 59 4 0 0 0 3
Suntec AJ6 Suntec J6
G
G

C.I.B. UNIGAS - M03997CB
11
Bleed
Bleeding in two-pipe operation is automatic : it is assured by a bleed flat on the piston. In one-pipe operation, the plug of a pressure
gauge port must be loosened until the air is evacuated from the system.
About the use of fuel pumps
zMake sure that the by-pass plug is not used in a single pipe installation, because the fuel unit will not function properly and damage
to the pump and burner motor could result.
zDo not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth,
thus obstructing them.
zAfter filling the tank, wait before starting the burner. This will give any suspended impurities time to deposit on the bottom of the
tank, thus avoiding the possibility that they might be sucked into the pump.
zOn initial commissioning a "dry" operation is foreseen for a considerable length of time (for example, when there is a long suction
line to bleed). To avoid damages inject some lubrication oil into the vacuum inlet.
zCare must be taken when installing the pump not to force the pump shaft along its axis or laterally to avoid excessive wear on the
joint, noise and overloading the gears.
zPipes should not contain air pockets. Rapid attachment joint should therefore be avoided and threaded or mechanical seal junc-
tions preferred. Junction threads, elbow joints and couplings should be sealed with removable sg component. The number of junc-
tions should be kept to a minimum as they are a possible source of leakage.
zDo not use PTFE tape on the suction and return line pipes to avoid the possibility that particles enter circulation. These could depo-
sit on the pump filter or the nozzle, reducing efficiency. Always use O-Rings or mechanical seal (copper or aluminium gaskets) jun-
ctions if possible.
zAn external filter should always be installed in the suction line upstream of the fuel unit.

C.I.B. UNIGAS - M03997CB
12
Light oil pumps
The pumps provided with these burners can be:
zPG60 - PG70: Suntec AJ6
zPG81: Suntec J6
Key
1 Pressure governor
2 Pressure gauge
3 Vacuum gauge
4 Solenoid valve
5 Nozzle
7 Suction
8 Return (by-pass plug inserted)
Suntec AJ6
Viscosity 2.8 - 75 cSt
Oil temperature 60°C max
Inlet maximum pressure 2bar
Inlet minimum pressure - 0.45 bar to avoid gasing
Rated speed 3600 rpm max.
Suntec J6 - J7
Oil viscosity 2.8 - 200 cSt
Oil temperature 0 - 90°C
Min. suction pressure - 0,45 barto avoid gasing
Max. suction pressure 1.5 bar
Max. return pressure 1.5 bar
Rotation speed 3600 rpm max.

C.I.B. UNIGAS - M03997CB
13
Connecting the light oil flexible hoses
To connect the flexible light oil hoses to the pump, proceed as follows, according to the pump provided:
1 remove the closing nuts Aand Ron the inlet and return connections of the pump;
2 screw the rotating nut of the two flexible hoses on the pump being careful to avoid exchanging the inlet and return lines: see the
arrows marked on the pump that show the inlet and the return (see prevoius paragraph).
3
Electrical connections
zRemove the cover from the burner electrical panel.
zExecute the electrical connections to the power supply terminal board as shown, check the direction of the fan-pump motor (see
next paragraph) and replace the electrical panel cover.
Suntec AJ6 Suntec J6
R
A
R
A

C.I.B. UNIGAS - M03997CB
14
ADJUSTMENTS
Priming the pump
Before carrying out any adjustment it is necessary to prime the light oil pump, proceeding as follows.
zEnsure the light oil valves are open (n. 6 in Fig. 5).
zStart the burner, light the photoresistor up after opening the solenoid valve and let the air bleed from the pressure gauge port.
Oil rate setting
The light oil flow rate is setting choosing a properly sized nozzle for the 1st and for the 2nd stage and setting the inlet pressure on the
pump. For the choice of the nozzles, refer to the following tables, for pressure setting of the pump see page 12.
Tab. 1 - Choosing the oil nozzles
ATTENTION: before starting the burner up, be sure that the manual cutoff valves are open. Be sure that the mains
switch is closed.
Before starting up the burner, make sure that the return pipe to the tank is not obstructed. Any obstruction would
cause the pump seal to break.
ATTENTION: During commissioning operations, do not let the burner operate with insufficient air flow (danger of formation
of carbon monoxide); if this should happen, make the fuel decrease slowly until the normal combustion values are achieved.
IMPORTANT! the combustion air excess must be adjusted according to the in the following chart:
Recommended combustion parameters
Fuel Recommended (%) CO2Recommended (%) O2
Light oil 11.5 ÷ 13 2.9 ÷ 4.9
Note: all pumps are set to 12 bar. The nozzle rate at low flame must be higher than the rate referred to the minimum
burner output.
PUMP PRESSURE (bar)
OUTPUT
10 12 14
(kW) (kCal/h) (kg/h) I° NOZZLE
G.P.H.
II° NOZZLE
G.P.H.
I° NOZZLE
G.P.H.
II° NOZZLE
G.P.H.
I° NOZZLE
G.P.H.
II° NOZZLE
G.P.H.
100 86.000 8,4 0,85 1,25 0,80 1,20 0,75 1,10
120 103.200 10,1 1,00 1,50 0,90 1,35 0,90 1,35
140 120.400 11,8 1,20 1,75 1,10 1,65 1,00 1,50
160 137.600 13,5 1,35 2,00 1,25 1,75 1,20 1,75
180 154.800 15,2 1,50 2,25 1,35 2,00 1,35 2,00
200 172.000 16,9 1,75 2,50 1,50 2,25 1,50 2,25
250 215.000 21,1 2,00 3,25 2,00 3,00 1,75 2,75
300 258.000 25,3 2,50 4,00 2,25 3,50 2,25 3,25
350 301.000 29,5 3,00 4,50 2,75 4,00 2,50 3,50
400 344.000 33,7 3,50 5,00 3,00 4,50 3,00 4,50
450 387.000 37,9 4,00 5,50 3,50 5,00 3,25 5,00
500 430.000 42,2 4,00 6,50 4,00 6,00 3,50 5,50
550 473.000 46,4 4,50 7,00 4,00 6,50 4,00 6,00
600 516.000 50,6 5,00 7,50 4,50 7,00 4,50 6,50
650 559.000 54,8 5,50 8,50 5,00 7,50 4,50 7,00
700 602.000 59,0 6,00 9,00 5,50 8,50 5,00 7,50
750 645.000 63,2 6,50 9,50 6,00 9,00 5,50 8,00
800 688.000 67,5 7,00 10,00 6,00 9,50 6,00 9,00
850 731.000 71,7 7,50 11,00 6,50 10,00 6,00 9,50
900 774.000 75,9 7,50 11,00 7,00 10,00 6,50 10,00
950 817.000 80,1 8,00 12,00 7,50 11,00 7,00 10,00
1000 860.000 84,3 8,50 13,00 8,00 12,00 7,50 11,00
1250 1.075.000 105,4 11,00 16,00 10,00 15,00 9,00 14,00
1500 1.290.000 126,5 13,00 19,50 12,00 18,00 11,00 16,00
1750 1.505.000 147,5 15,00 22,00 14,00 20,00 13,00 19,50
2000 1.720.000 168,6 17,00 26,00 16,00 24,00 15,00 22,00

C.I.B. UNIGAS - M03997CB
15
Tab. 2 - Light oil nozzles rate
NOZZLE
G.P.H.
PUMP PRESSURE (bar)
NOZZLE
G.P.H.
6 101112131415161718192024
LIGHT OIL FLOW RATE (kg/h)
0,30 0,9 1,1 1,2 1,3 1,3 1,4 1,4 1,5 1,5 1,5 1,6 1,6 1,8 0,30
0,35 1,0 1,3 1,4 1,5 1,5 1,6 1,6 1,7 1,7 1,8 1,8 1,9 2,1 0,35
0,40 1,2 1,5 1,6 1,7 1,7 1,8 1,9 1,9 2,0 2,1 2,1 2,2 2,4 0,40
0,45 1,3 1,7 1,8 1,9 2,0 2,0 2,1 2,2 2,2 2,3 2,4 2,4 2,7 0,45
0,50 1,5 1,9 2,0 2,1 2,2 2,3 2,3 2,4 2,5 2,6 2,6 2,7 3,0 0,50
0,55 1,6 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,7 2,8 2,9 3,0 3,3 0,55
0,60 1,8 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,2 3,6 0,60
0,65 1,9 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,9 0,65
0,70 2,1 2,7 2,8 2,9 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 4,2 0,70
0,75 2,2 2,9 3,0 3,1 3,3 3,4 3,5 3,6 3,7 3,9 4,0 4,1 4,4 0,75
0,80 2,4 3,1 3,2 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,2 4,3 4,7 0,80
0,85 2,5 3,3 3,4 3,6 3,7 3,9 4,0 4,1 4,2 4,4 4,5 4,6 5,0 0,85
0,90 2,7 3,4 3,6 3,8 3,9 4,1 4,2 4,4 4,5 4,6 4,8 4,9 5,3 0,90
1,00 3,0 3,8 4,0 4,2 4,4 4,5 4,7 4,8 5,0 5,1 5,3 5,4 5,9 1,00
1,10 3,3 4,2 4,4 4,6 4,8 5,0 5,2 5,3 5,5 5,7 5,8 6,0 6,5 1,10
1,20 3,6 4,6 4,8 5,0 5,2 5,4 5,6 5,8 6,0 6,2 6,3 6,5 7,1 1,20
1,25 3,7 4,8 5,0 5,2 5,5 5,7 5,9 6,1 6,2 6,4 6,6 6,8 7,4 1,25
1,35 4,0 5,2 5,4 5,7 5,9 6,1 6,3 6,5 6,7 6,9 7,1 7,3 8,0 1,35
1,50 4,4 5,7 6,0 6,3 6,5 6,8 7,0 7,3 7,5 7,7 7,9 8,1 8,9 1,50
1,65 4,9 6,3 6,6 6,9 7,2 7,5 7,7 8,0 8,2 8,5 8,7 8,9 9,8 1,65
1,75 5,2 6,7 7,0 7,3 7,6 7,9 8,2 8,5 8,7 9,0 9,2 9,5 10,4 1,75
2,00 5,9 7,7 8,0 8,4 8,7 9,1 9,4 9,7 10,0 10,3 10,6 10,8 11,9 2,00
2,25 6,7 8,6 9,0 9,4 9,8 10,2 10,6 10,9 11,2 11,6 11,9 12,2 13,3 2,25
2,50 7,4 9,6 10,0 10,5 10,9 11,3 11,7 12,1 12,5 12,8 13,2 13,5 14,8 2,50
2,75 8,2 10,5 11,0 11,5 12,0 12,5 12,9 13,3 13,7 14,1 14,5 14,9 16,3 2,75
3,00 8,9 11,5 12,0 12,6 13,1 13,6 14,1 14,5 15,0 15,4 15,8 16,2 17,8 3,00
3,25 9,6 12,4 13,1 13,6 14,2 14,7 15,2 15,7 16,2 16,7 17,2 17,6 19,3 3,25
3,50 10,4 13,4 14,1 14,7 15,3 15,9 16,4 17,0 17,5 18,0 18,5 19,0 20,8 3,50
4,00 11,9 15,3 16,1 16,8 17,5 18,1 18,8 19,4 20,0 20,5 21,1 21,7 23,7 4,00
4,50 13,3 17,2 18,1 18,9 19,6 20,4 21,1 21,8 22,5 23,1 23,8 24,4 26,7 4,50
5,00 14,8 19,1 20,1 21,0 21,8 22,7 23,4 24,2 25,0 25,7 26,4 27,1 29,7 5,00
5,50 16,3 21,1 22,1 23,1 24,0 24,9 25,8 26,6 27,5 28,3 29,0 29,8 32,6 5,50
6,00 17,8 23,0 24,1 25,2 26,2 27,2 28,1 29,1 30,0 30,8 31,7 32,5 35,6 6,00
6,50 19,3 24,9 26,1 27,3 28,4 29,4 30,5 31,5 32,5 33,4 34,3 35,2 38,6 6,50
7,00 20,8 26,8 28,1 29,4 30,6 31,7 32,8 33,9 34,9 36,0 36,9 37,9 41,5 7,00
7,50 22,2 28,7 30,1 31,5 32,7 34,0 35,2 36,3 37,4 38,5 39,6 40,6 44,5 7,50
8,00 23,7 30,6 32,1 33,6 34,9 36,2 37,5 38,7 39,9 41,1 42,2 43,3 47,5 8,00
8,50 25,2 32,5 34,1 35,7 37,1 38,5 39,9 41,2 42,4 43,7 44,9 46,0 50,4 8,50
9,00 26,7 34,5 36,1 37,7 39,3 40,8 42,2 43,6 44,9 46,2 47,5 48,7 53,4 9,00
9,50 28,2 36,4 38,2 39,8 41,5 43,0 44,5 46,0 47,4 48,8 50,1 51,4 56,4 9,50
10,00 29,7 38,3 40,2 41,9 43,7 45,3 46,9 48,4 49,9 51,4 52,8 54,1 59,3 10,00
11,00 32,6 42,1 44,2 46,1 48,0 49,8 51,6 53,3 54,9 56,5 58,1 59,6 65,2 11,00
12,00 35,6 45,9 48,2 50,3 52,4 54,4 56,3 58,1 59,9 61,6 63,3 65,0 71,2 12,00
13,00 38,6 49,8 52,2 54,5 56,8 58,9 61,0 63,0 64,9 66,8 68,6 70,4 77,1 13,00
13,50 40,0 51,7 54,2 56,6 58,9 61,2 63,3 65,4 67,4 69,4 71,3 73,1 80,1 13,50
14,00 41,5 53,6 56,2 58,7 61,1 63,4 65,7 67,8 69,9 71,9 73,9 75,8 83,0 14,00
15,00 44,5 57,4 60,2 62,9 65,5 68,0 70,3 72,6 74,9 77,1 79,2 81,2 89,0 15,00
16,00 47,5 61,3 64,3 67,1 69,9 72,5 75,0 77,5 79,9 82,2 84,4 86,6 94,9 16,00
17,00 50,4 65,1 68,3 71,3 74,2 77,0 79,7 82,3 84,9 87,3 89,7 92,1 100,8 17,00
18,00 53,4 68,9 72,3 75,5 78,6 81,5 84,4 87,2 89,9 92,5 95,0 97,5 106,8 18,00
19,00 56,4 72,7 76,3 79,7 82,9 86,1 89,1 92,0 94,9 97,6 100,3 102,9 112,7 19,00
19,50 57,8 74,7 78,3 81,8 85,1 88,3 91,4 94,4 97,4 100,2 102,9 105,6 115,7 19,50
20,00 59,3 76,6 80,3 83,9 87,3 90,6 93,8 96,9 99,8 102,7 105,6 108,3 118,6 20,00
22,00 65,2 84,2 88,3 92,3 96,0 99,7 103,2 106,6 109,8 113,0 116,1 119,1 130,5 22,00
24,00 71,2 91,9 96,4 100,7 104,8 108,7 112,5 116,2 119,8 123,3 126,7 130,0 142,4 24,00
25,00 74,1 95,7 100,4 104,9 109,1 113,3 117,2 121,1 124,8 128,4 131,9 135,4 148,3 25,00
26,00 77,1 99,6 104,4 109,1 113,5 117,8 121,9 125,9 129,8 133,6 137,2 140,8 154,2 26,00

C.I.B. UNIGAS - M03997CB
16
Hydraulic scheme - operating principle
Fig. 8 - IGNITION AND LOW FLAME
Voltage on solenoid valve EVG1
Fig. 9 - HIGH FLAME
Voltage on solenoid valves EVG, EVG2, EVG3
Fig. 10 - SHUTDOWN
There isn’t any solenoid valves activated
Keys
EVG1 - Solenoid valve, first stage, NC
EVG1 - Solenoid valve, second stage, NC
M - Air damper drive
P - Pump

C.I.B. UNIGAS - M03997CB
17
Hydraulic circuit - components arrangement
Air adjustment
zLow flame setting
To set the low flame, proceed as follows:
1 open the contact of the second stage regulator;
2 unscrew the lock nut (Fig. 11-2) and twist directly the body of the air damper jack (Fig. 11-1): turn clockwise to increase the air flow
of the low flame stage; turn counterclockwise to decrease the air flow;
3 the air flow change is shown by the air damper index (Fig. 11-5),
4 at the end of settings, tighten the nut (Fig. 11-2).
zHigh flame setting
To set the high flame proceed as follow.
1 Close the contact of the second stage regulator;
2 loose the nut 3 and turn the nut 4: urning counterclockwise the air flow in high flame mode is increased, turning clockwise it decre-
ases.
3 The air flow change is indicated by the move of the air damper index 5.
4 At the end of settings, tighten the nut 3.
N:B: during the point “b” regulations, the point “a” remains unchanged.
Fig. 11
hydraulic jack
oil pump delivery
1
2
3
4
5high flame air adjustment
low flame air adjustment
oil return pressure gauge plug

C.I.B. UNIGAS - M03997CB
18
Combustion head adjustment
The burner is factory-set with the combustion head at the "MAX." position (Fig. 13), corresponding to the maximum output. To operate
at a lower output, move back the combustion head towards the "MIN." position, twisting the VRT screw (Fig. 12 and Fig. 13)
clockwise.
N.B.: loose the screw VB before settings and tight it at the end of adjustments. Don’t let the burner operate with the combu-
stion head in the “MIN” position.
Fig. 12 Fig. 13

C.I.B. UNIGAS - M03997CB
19
LIMITATIONS OF USE
THE BURNER IS AN APPLIANCE DESIGNED AND CONSTRUCTED TO OPERATE ONLY AFTER BEING CORRECTLY CON-
NECTED TO A HEAT GENERATOR (E.G. BOILER, HOT AIR GENERATOR, FURNACE, ETC.), ANY OTHER USE IS TO BE CONSI-
DERED IMPROPER AND THEREFORE DANGEROUS.
THE USER MUST GUARANTEE THE CORRECT FITTING OF THE APPLIANCE, ENTRUSTING THE INSTALLATION OF IT TO
QUALIFIED PERSONNEL AND HAVING THE FIRST COMMISSIONING OF IT CARRIED OUT BY A SERVICE CENTRE AUTHORI-
SED BY THE COMPANY MANUFACTURING THE BURNER.
A FUNDAMENTAL FACTOR IN THIS RESPECT IS THE ELECTRICAL CONNECTION TO THE GENERATOR’S CONTROL AND
SAFETY UNITS (CONTROL THERMOSTAT, SAFETY, ETC.) WHICH GUARANTEES CORRECT AND SAFE FUNCTIONING OF
THE BURNER.
THEREFORE, ANY OPERATION OF THE APPLIANCE MUST BE PREVENTED WHICH DEPARTS FROM THE INSTALLATION
OPERATIONS OR WHICH HAPPENS AFTER TOTAL OR PARTIAL TAMPERING WITH THESE (E.G. DISCONNECTION, EVEN
PARTIAL, OF THE ELECTRICAL LEADS, OPENING THE GENERATOR DOOR, DISMANTLING OF PART OF THE BURNER).
NEVER OPEN OR DISMANTLE ANY COMPONENT OF THE MACHINE.
OPERATE ONLY THE MAIN SWITCH, WHICH THROUGH ITS EASY ACCESSIBILITY AND RAPIDITY OF OPERATION ALSO
FUNCTIONS AS AN EMERGENCY SWITCH, AND ON THE RESET BUTTON.
IN THE EVENT OF REPEATED LOCKOUTS, DO NOT PERSIST WITH THE RESET BUTTON AND CONTACT QUALIFIED PER-
SONNEL WHO WILL PROCEED TO ELIMINATE THE MALFUNCTION.
WARNING: DURING NORMAL OPERATION THE PARTS OF THE BURNER NEAREST TO THE GENERATOR (COUPLING
FLANGE) CAN BECOME VERY HOT, AVOID TOUCHING THEM SO AS NOT TO GET BURNT.
OPERATION
zCheck the flame control device is not in the lockout position, in this case reset it with the release button.
zCheck all the thermostats and pressure switches give the all clear to operate to the burner.
zThe burner is now operating in the low flame mode; after some seconds, the second stage operation begins or the burner remains in
the low flame mode, depending on the needs of the plant.
PART II: OPERATION

C.I.B. UNIGAS - M03997CB
20
At least once a year carry out the maintenance operations listed below. In the case of seasonal servicing, it is recommended to carry
out the maintenance at the end of each heating season; in the case of continuous operation the maintenance is carried out every 6
months.
ROUTINE MAINTENANCE
zClean and examine the oil filter cartdrige and replace it if necessary;
zexamine the flexible oil pipes and check for possible leaks;
zcheck and clean the filter on the fuel pump: bilter must be thoroughly cleaned at least once in a season to ensure correct working of
the fuel unit. To remove the filter, unscrew the four screws on the cover. When reassemble, make sure that the filter is mounted
with the feet toward the pump body. If the gasket between cover and pump housing should be damaged, it must be replaced;
zdismantle, examine and clean the combustion head (see next paragraph); reassembling the combustion head be careful to respect
the measures in Fig. 17;
zcheck the electrodes and their ceramic insulators, clean and adjust the electrodes or, if necessary, replace them (see related para-
graph);
zdismantle and clean the oil nozzles (IMPORTANT: don’t use metallic or sharp utensils but solvent or steam to clean the nozzles); at
the end of these maintenance procedures, refit the burner, turn it on and verify the combustion: if in doubt, replace the defective noz-
zle or nozzles. If the burner is used intensively, it is recommended to replace the nozzles at the start of the operating season.
zcheck and clean carefully the flame detection photoelectric cell, if necessary replace it and, if in doubt, verify the detection circuit with
the burner in operation.
Removing the combustion head
1 Remove the burner cover C;
2 remove the photoresistor from its site;
3 unscrew the connectors from the 2 oil pipes - Fig. 16 (use 2 spanners to avoid loosening the connections to the distribution block);
4 (only mod. PG60) loose the screw VRT to free the threaded rod AR, then unscrew the 2 screws V which hold the washer R and the
screw VRT;
5 remove the complete assembly as shown in Fig. 15 (in models PG70 - PG81 )the adjusting screw VRT is pulled out with the com-
bustion head assembly
Note: to re-assembly, follow the procedure in the reversed order.
WARNING: ALL OPERATIONS ON THE BURNER MUST BE CARRIED OUT WITH THE MAINS DISCONNECTED AND
THE FUEL MANAUL CUTOFF VALVES CLOSED!
ATTENTION: READ CAREFULLY THE “WARNINGS” CHAPTER AT THE BEGINNIG OF THIS MANUAL..
Fig. 14
PART III: MAINTENANCE
C
AR
VRT
R
Fig. 15
C
E
Fig. 16